Motor cooling system

CROSS-REFERENCE TO RELATED APPLICATIONS

The instant application for U.S. Letters Patent claims the benefit of copending U.S. Provisional Application Ser. No. 60/123,553, filed Mar. 10, 1999.

BACKGROUND OF THE INVENTION

The instant invention relates generally to cooling systems and more particularly to an air-cycle cooling system for an electric motor. Large electric motors, for example alternating current (AC) induction motors, generate tremendous amounts of heat as a result of the electromagnetic fields therein. The internal heat build-up significantly reduces the efficiency of the motor, particularly in high-density power applications. In electric motor applications heat is particularly undesirable due to the increase in electrical resistance through the motor windings associated with an increase in temperature. AC induction motors utilizing vector drives are particularly prone to heat build-up in the rotors thereof. The removal of this heat is required for efficient operation of the motor.

Known in the art motor cooling systems employ a variety of cooling methods including air fans and various liquid coolants, for example water or transmission fluid, circulated through jackets surrounding the motor frame. In these systems, heat builds up in the rotor and stator and radiates to the inner surface of the water jacket surrounding the motor. Water (or other industrial coolant such as liquid nitrogen) is continuously circulated throughout the water jacket surrounding the motor to dissipate heat from the interior surfaces thereof.

Conventional water jacket motor cooling systems can provide sufficient cooling for ordinary large motor applications, but motor efficiency is unimpressive. In high power density applications, a great deal of power that would otherwise translate into shaft horespower is lost due to heat build-up in the motor's rotor and stator. Vector drive motor control systems have a particular tendency to cause heat build-up in the rotor surfaces, thereby requiring heat to radiate outwardly through the stator thence to the water jacket interior surfaces. This results in a very poor heat transfer path and an inability to provide adequate motor cooling for high power density applications.

Additionally, known-in-the-art liquid cooling systems greatly increase the expense of a given motor application due to the necessity of providing a coolant supply, piping, temperature and pressure regulation, and the various labor and material costs associated therewith. Furthermore, the effects of chronic and excessive heat build-up are deleterious to electric motors. Exotic industrial coolants that prevent excessive heat build-up for very large motor applications can be cost prohibitive.

SUMMARY OF THE INVENTION

The aforementioned problems are solved by the cooling system and method of the present invention that provides a directed airflow to the interior of an electric motor to remove undesirable heat therefrom. The instant invention introduces cooling fluid, preferably compressed air through an end plate of an electric motor utilizing a nozzle, or a plurality thereof, disposed radially outwardly of the end turns of a stator.

The instant invention is designed to operate using “shop air”, widely available in most industrial settings, as a preferred cooling fluid. The use of compressed air provides a tremendous cost savings by obviating the need for specialized liquid cooling systems in large motor applications. Additionally, the energy used by industrial compressors to supply “shop air”, throughout an industrial plant is partially recovered by employing the air as a cooling fluid. The pressurized shop air is forced through a nozzle, or a plurality thereof, thence into the interior of an electric motor thereby creating a rapid pressure drop as the air enters a chamber in the motor. Since the volume of the compressed air exiting the nozzles is essentially constant, the gas law (PV=nRT) requires the air temperature to exhibit a proportional decrease.

The cool air exiting the nozzles is directed tangentially to the axis of the rotor at a plurality of points outwardly of the end turns of the stator. This cool, high velocity fluid travels through the channels formed by the looped electrical conductors inherent in conventional stator end turns, and is thereby directed radially inwardly across a rotor end disc, proximate the rotor shaft, and then into the slight air gap between the rotor and stator, thus efficiently removing heat from the both rotor and stator surfaces. The rotation of the rotor and a slight positive pressure maintained between the upstream and downstream ends of the motor provide for high velocity cooling fluid within the rotor-stator gap.

The cool air then travels inwardly across the end disk of the motor to transfer heat therefrom. The air then exits the motor through a plurality of exhaust ports disposed in a second motor end plate located opposite the drive end thereof. The exhaust ports are preferably sized to maintain a slight positive pressure differential between the chamber at the drive end of the motor and the chamber at the exhaust end thereof, depending upon the pressure of the cooling air supply. This positive pressure differential enhances the flow of cooling fluid through the rotor-stator gap, providing exceptional heat transfer. In one embodiment of the instant invention a plurality of exhaust ducts having inlets located radially outwardly of the stator end turns are disposed in fluid communication with the exhaust ports to direct the cooling fluid exiting the rotor-stator gap across and through the stator end turns, thereby enhancing overall heat transfer.

The instant invention is readily retrofitted to existing electric motor applications, requiring only several apertures to be bored in one end plate for installation of the plurality of nozzles, and an exhaust port or ports in the opposed end plate. In most industrial settings, compressed air to be used as cooling fluid is readily available via plant piping. The motor may be equipped with a water jacket or similar cooling apparatus that remains unused for purposes of the instant invention

Therefore, one object of the instant invention is an inexpensive cooling system for conventional electric motors, of particular benefit in high power density applications.

Another object of the instant invention is a cooling system for an electric motor employing widely available “shop air” as a cooling fluid, thereby obviating the need for costly liquid cooling systems.

Another object of the instant invention is a cooling system for an electric motor that recovers a portion of the energy expended in the production of compressed air in industrial facilities.

Another object of the instant invention is a cooling system for an electric motor utilizing a plurality of fluid nozzles to direct cooling fluid to cool the rotor and stator thereof, thereby providing a dramatic increase in motor efficiency.

Another object of the instant invention is a cooling system for an electric motor that permits the operation thereof in extremely high power density applications, wherein conventional cooling systems fail.

Yet another object of the instant invention is a cooling system for an electric motor that utilizes the existing channels present in conventional stator end turns and motor windings as flow paths for cooling fluid, thereby affording exceptional heat transfer.

Yet another object of the instant invention is a cooling system for an electric motor that is readily installed in existing motor applications.

Additional objects, features, and advantages of the present invention will become apparent from the subsequent detailed description, taken in conjunction with the accompanying drawing figures.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view of an electric motor in accordance with the instant invention.

FIG. 2 is a perspective view of a cooling nozzle of the instant invention.

FIG. 3 is a view of the instant invention taken along the line <b>3</b>—<b>3</b> of FIG. <b>1</b>.

FIG. 4 is a cross-sectional view of an electric motor in accordance with an alternate embodiment of the instant invention.

FIG. 5 is a view of the instant invention taken along the line <b>5</b>—<b>5</b> of FIG. <b>1</b>.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

As shown in FIG. 1, and in accordance with a preferred constructed embodiment of the instant invention, a motor cooling system <b>10</b> is shown in operative association with a conventional alternating current (AC) induction motor <b>20</b>, having a closed housing comprising a motor frame <b>30</b> and first and second opposed end plates <b>40</b> and <b>50</b> respectively, disposed at opposite ends of the motor frame <b>30</b>. The motor <b>20</b> further comprises a conventional rotor <b>60</b> mounted on a shaft <b>62</b> journaled on bearings <b>64</b> and capable of rotation about a central axis. The rotor shaft <b>62</b> extends at either end through corresponding apertures <b>42</b> and <b>52</b> in the opposed end plates <b>40</b> and <b>50</b>. The rotor further comprises a pair of opposed, generally circular end discs <b>66</b>, disposed at opposite ends thereof.

The motor further comprises a conventional stator <b>70</b>, secured to the motor frame <b>30</b> and disposed radially outwardly of the rotor <b>60</b> such that a small air filled gap <b>72</b> is present therebetween. The stator <b>70</b> is typically comprised of a plurality of generally circular steel laminated discs having a plurality of radially inwardly directed slots disposed therein. The plurality of discs are stacked together wherein the plurality of slots form a plurality of axial channels through which stator coils <b>74</b> comprised of a wire conductor pass. The coils <b>74</b> have a plurality of end turns <b>76</b> where the conductors are routed from one axial channel to another.

Due to the proximity of the rotor <b>60</b> and the stator <b>70</b> at the air gap <b>72</b>, the interior of the motor is in essence divided into a pair of chambers, <b>80</b> and <b>90</b> respectively . Chamber <b>80</b>, hereinafter the upstream chamber, is bounded by end plate <b>40</b> on a first side, the rotor <b>60</b> and stator <b>70</b> on a second side, and the motor frame <b>30</b> at the periphery. Similarly, chamber <b>90</b>, hereinafter the downstream chamber, is bounded by end plate <b>50</b> on a first side, the rotor <b>60</b> and stator <b>70</b> on a second side, and the motor frame <b>30</b> at the periphery. While the instant invention is shown in operative association with an AC induction motor, it is adaptable for use with all varieties of electric motors.

Referring to FIGS. 1 and 2, the motor cooling system <b>10</b> of the present invention comprises a nozzle <b>100</b> inserted through an aperture <b>44</b> in the first end plate <b>40</b> of the motor <b>20</b>. The nozzle has an inlet <b>102</b> disposed externally of said motor <b>20</b> and an outlet <b>104</b> disposed internally thereof. The inlet <b>102</b> is designed to accept a cooling fluid for admission into the interior of the motor <b>20</b>, specifically, compressed air as generated and readily available in most industrial settings. The outlet <b>104</b> is oriented to direct the cooling fluid circumferentially around the interior of the motor frame <b>30</b>, proximate the end turns <b>76</b> of the stator <b>70</b>.

As best seen in FIG. 2, the nozzle inlet <b>102</b> comprises a generally cylindrical portion <b>106</b> adapted to accept a source of cooling fluid, preferably compressed air, adjacent a conical portion <b>108</b> that tapers to a tubular portion <b>110</b> extending through the aperture <b>44</b> in the end plate <b>40</b>. The tubular portion <b>110</b> has an angled section <b>112</b> therein to direct the cooling fluid circumferentially of the motor <b>20</b> as it exits the nozzle outlet <b>104</b>.

The motor cooling system further comprises a plurality of exhaust ports <b>120</b>, best seen in FIGS. 1 and 3, disposed in the second end plate <b>50</b> proximate the periphery thereof to facilitate the release of cooling fluid from the downstream chamber <b>90</b>. Locating the exhaust ports <b>120</b> as far radially outwardly of the end plate <b>50</b> as practicable forces the cooling fluid to travel a greater distance prior to exiting the motor <b>20</b>, thereby facilitating heat transfer. As shown in FIG. 1, the exhaust ports <b>120</b> are enclosed, at the exterior of the end plate <b>50</b>, by a plurality of exhaust silencers <b>130</b> to reduce the ambient noise produced by the exhausted cooling fluid. The silencers <b>130</b> place no restriction on the volume of cooling fluid flowing through the exhaust ports <b>120</b>. The exhaust silencers <b>130</b> may be utilized in applications requiring higher cooling fluid pressures, wherein the noise generated by the exhausted cooling fluid is undesirable or unsafe.

In an alternative embodiment of the instant invention as shown in FIG. 4, a plurality of exhaust ducts <b>140</b> having inlets <b>142</b> located radially outwardly of the end turns <b>76</b> of the stator <b>70</b> and outlets <b>144</b> in fluid communication with the exhaust ports <b>120</b> direct the cooling air to exit the motor <b>20</b> proximate the end turns <b>76</b> thereof. This feature confers particular advantage to the cooling capacity of the system <b>10</b> by initiating a fluid flow path in the downstream chamber <b>90</b> radially outwardly proximate the rotor end disc <b>66</b>, around the end turns <b>76</b> of the stator <b>70</b>, proximate the rotor shaft <b>62</b>, thence outwardly to the exhaust ducts <b>140</b>, wherein the boundary layer of cooling fluid remains turbulent, thereby providing exceptional heat transfer from the aforementioned motor surfaces to the cooling fluid prior to exhaust.

In another alternative embodiment, the exhaust ports <b>120</b> are sized to have a total cross-sectional area that provides a positive pressure differential between the upstream chamber <b>80</b> of the motor <b>20</b> and the downstream chamber <b>90</b> thereof, for a given pressure of cooling air introduced via the nozzle <b>100</b>. This feature of the invention maintains a positive pressure differential between the chamber <b>80</b> and the chamber <b>90</b> wherein cooling fluid exiting the channels formed by the end turns <b>76</b> of the stator <b>70</b> is drawn into the gap <b>72</b> between the rotor <b>60</b> and the stator <b>70</b>. The rotation of the rotor <b>60</b> adds a tangential component to the cooling fluid flow path, thereby creating a helical fluid flow path through the rotor-stator gap, wherein the cooling fluid attains very high velocity. This “ramjet effect” flow path through the rotor-stator gap <b>72</b> enhances heat transfer to the cooling fluid while obviating the need to drive heat from the rotor <b>60</b> through the stator <b>70</b> prior to removal thereof, as presently practiced in conventional motor cooling systems. In this embodiment of the instant invention, the pressure in the downstream motor chamber <b>90</b> is preferably maintained above atmospheric pressure to facilitate cooling fluid flow through the exhaust ports.

For ease of maintaining and monitoring the aforementioned pressure differential between chambers <b>80</b> and <b>90</b>, a pair of conventional pressure gauges <b>150</b> in fluid communication with the respective chambers may be disposed in ports provided therefor. Additionally, where cooling requirements are such that high pressure shop air is required, a pair of bearing air seals <b>152</b> may be disposed circumferentially around the shaft <b>62</b> of the rotor <b>60</b> at opposed ends thereof for the purpose of protecting the shaft bearings <b>64</b> from the deleterious effects of pressurization.

The cooling system <b>10</b> of the instant invention may also be practiced by providing a plurality of nozzles <b>100</b> extending through a plurality of apertures <b>44</b> disposed in endplate <b>40</b>, as shown in FIG. <b>5</b>. This embodiment of the instant invention permits the introduction of a greater volume of cooling fluid at a plurality of locations radially outwardly of said end turns <b>76</b>, facilitating heat transfer therefrom. This embodiment of the instant invention is particularly advantageous in high power density motor applications wherein a tremendous amount of heat is generated by the electromagnetic fields in the rotor <b>60</b> and stator <b>70</b>.

In operation, the compressed cooling fluid expands rapidly through the plurality of nozzles, thus providing a dramatic temperature drop. The fluid is initially directed above the end turns <b>76</b> of the stator <b>70</b>, tangentially to the axis of rotation of the rotor <b>60</b>. The stator end turns <b>76</b> form helical channels that provide a path for the cooling fluid thereby effecting excellent heat transfer. The cooling fluid then travels radially inwardly, contacting the surfaces of the rotor end disc <b>66</b> proximate the upstream chamber <b>80</b>. This air path cools the rotor <b>60</b> end disc <b>66</b> and further cools the shaft <b>62</b> thereof. The cooling fluid flowing past the stator end turns <b>76</b> is drawn into the gap <b>72</b> between the rotor <b>60</b> and stator <b>70</b> by operation of the positive pressure differential where it attains high velocity due to the rotation of the rotor <b>60</b>. This cooling fluid transfers heat from the rotor and stator prior to exiting through the exhaust ports <b>120</b> or the ducts <b>140</b> in fluid communication therewith.

Proper direction and velocity of the cooling fluid through the plurality of nozzles to the large surface area of the stator <b>70</b> and rotor <b>60</b> assists in keeping the cooling fluid boundary layers turbulent at all times, thereby resulting in superior heat transfer characteristics.

While specific embodiments of the instant invention have been described in detail, those with ordinary skill in the art will appreciate that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of the invention, which is to be given the full breadth of the appended claims and any and all equivalents thereof.